TQM Introduction
TQM Introduction
TQM Introduction
Some questions . . .
Does higher quality has any relation with business performance? Does higher quality means more cost and more time Or quality is free? Operational problems faced by organizations can be generalized? What management experts have advised to improve aver all operation?
Shall we learn lesson from management experts or try our own methods
Total Quality Management
Contents
Quality Definition
Quality Movements
History of Quality Paradigms Quality Control & Assurance
Quality Definition
Quality is the conformance requirements. (Crosby in 1979)
Fitness for use. (Juran 1970) The degree to which a system, component, or process meets specified requirements. (IEEE)
to
Quality Gurus
Walter A. Shewhrat Dr. W. Edwards Deming Dr. Joseph M. Juran Philip Crosby Kaoru Ishikawa
Quality Movements
Japanese were badly defeated in World War II. Their industrial and financial bases were in chaos. Japan had no natural resource and limited source of food for their people. The quality movement began in Japan in 1946 with the U.S. Occupation Force's mission to revive and restructure Japan's communications equipment industry. Dr. Deming was invited by the Union of Japanese Scientists and Engineers to Japan in 1947. In 1954, Dr. Joseph Juran of the United States raised the level of quality management from the factory to the total organization in Japan.
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Quality Movements
Results from Japans implementation from American
3- TQM Paradigm
Potential customers determine what to design and build. Higher quality obtained by focusing on preventing defects and continuously reducing variability in all processes.
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Quality Evolution
Proactive Approach
Prevention Stop defects at source. Zero defects
3
4
Incorporates QC/QA activities into a company-wide system aimed at satisfying the customer. (involves all organizational functions)
Quality Assurance
Planned and systematic actions to insure that products or services conform to company requirements
Reactive Approach
Detection Finding & Fixing mistakes
1 2
Quality Control
Operational techniques to make inspection more efficient & to reduce the costs of quality. (example: SPC) Inspect products
Inspection
Quality Control
The purpose of quality control is to uncover defects and have them corrected so that defectfree products will be produced. Quality control is limited to looking at products . Quality control is testing the final product against product quality standards. Quality control is operational techniques that are used to fulfill requirements for product quality.
Juran says, software quality control is the process of measuring actual quality, comparing this to some standard, and then acting on the discrepancy.
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Quality Assurance
Quality assurance is oriented toward preventing defects. It is defined by those activities that modify the development processes to prevent the introduction of defects. Quality assurance is more concerned with the processes that produce the final product, and making sure that quality is part of each phase. QA is about maturing the process towards minimum defect. It is about balancing methodology, leadership, and technology. It is about taking into account human factors as well as technological ones.
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TQM Philosophy
You must put a quality product into QC before you can expect to get out one, otherwise wastage (or rework) will be very high.
Pillars of TQM
1- Customer Focus: Studying customer needs, gathering customer requirements, and measuring and managing customer satisfaction. Customer satisfaction is seen as the company's highest priority. The company believes that it will only be successful if its customers are satisfied. 2- Process Management: Develop a production process that reduce the product variations. Applying the same process; the same product should be produces with the same level of quality every time. Teams are process-oriented, and interact with their internal customers to deliver the required results. Management's focus is on controlling the overall process, and rewarding teamwork.
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Pillars of TQM
3- Human side of Quality: TQM environment requires a committed and well-trained work force that participates fully in quality improvement activities.
On-going education and training of all employees supports the drive for quality. 4- Continuous Improvement: TQM recognizes that product quality is the result of process quality. As a result, there is a focus on continuous improvement of the company's processes.
This will lead to an improvement in process quality. In turn this will lead to an improvement in product quality. Measurement and analysis id the tool that has been used for that.
Pillars of TQM
T. Q. M.
Customer Focus Process Employee Training Management & Empowerment Continuous Improvement
(through measurement and analysis)
Leadership
The ability of top management to establish, practice, and lead a long-term vision for the firm, driven by changing customer requirements, as opposed to an internal management control role. Lack of top management commitment is one of the reasons for the failure of TQM efforts (Brown et al. 1994).
A predominant requirement for quality management is that strong commitment from top management is vital.
To be an effective leader in most modern firms, the top manager must continue to develop and learn. Knowledge of the business and continual learning are essential prerequisites to effective leadership (DuBrin, 1995).
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Leadership
In order to effectively lead the firm, top management must be committed to provide education and training to employees and regarding them as valuable resources of the firm. Top management must be committed to allocating sufficient resources to prevent, as well as repair, quality problems. Top management should discuss quality frequently; by having session on the topic and asking questions about quality at every staff meeting.
Top management must train and coach employees to assess, analyze, and improve work processes (Deming, 1986).
Employee Participation
Employee participation can be defined as the degree to which employees in a firm engage in various quality management activities. By participating in quality management activities, employees acquire new knowledge, see the benefits of the quality disciplines, and obtain a sense of accomplishment by solving quality problems. A remarkable characteristic of employee participation is teamwork. Breakdown barriers between departments. People in research, design, sales, and production must work as a team (Demings 9th point). If several knowledgeable people are brought into the decision-making process, a number of worthwhile possibilities may be uncovered.
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Employee Participation
TQM implementation practice is formation of short-term problem-solving teams. Problem-solving teams work on a wide variety of tasks, ranging from cross-functional involvement in tackling quality problems to solving within-functional quality problems. TQM firms create employee suggestion systems. Production workers should regularly participate in operational decisions such as planning, goal setting, and monitoring of performance. They are encouraged to make suggestions and take a relatively high degree of responsibility for overall performance. Employees should be encouraged to inform managers or supervisors concerning conditions that need correction (e.g., process defects, incompetent staff and poor tools).
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Reward is defined as benefits, such as increased salary, bonuses and promotion, which are conferred for generally superior performance with respect to goals (Juran and Gryna, 1993). Public recognition is an important source of human motivation.
Important feature of any quality improvement program is the showing of due recognition for improved performance by any individual, section, department or division within the firm.
A large majority of firms implementing TQM modify their performance measurement and reward systems so that achievement of specific quality goals can be assessed and rewarded.
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Performance Evaluation
Evaluation can identify the difference between actual and the expected performance. Evaluation information should be communicated to employees in order to encourage employees to make things better. Uncontrolled variance in processes or outcomes is the primary cause of quality problems and must be evaluated and controlled by those who perform the firms front-line work.
It is important to note that the major aim of evaluation is improvement, NOT criticism.
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7. 8. 9.
Learn from problems. They continually try to improve communications. They continually demonstrate their commitment to quality. 10. Choose suppliers on the basis of quality, not price. 11. Establish organizational systems to support the quality effort. 12. Encourage and recognize team effort.
Understand People
People,normally, need security and independence at the same time. People are sensitive to rewards and punishments and yet are also strongly self-motivated.
Definition
Priorities
Product-oriented
2nd to service and cost
Customer-oriented
Equals of service and cost Long-term Prevention System Everyone Teams Life-cycle costs,partnership Delegate, coach, facilitate and mentor
Decisions
Emphasis Errors Responsibility Problem Solving Procurement Managers Role
Short-term
Detection Operations Quality control Managers Price Plan, assign, control, and enforce
10
Software Quality
Improvement Multiplier
Years